FTTH Drop Cable Production: Step-by-Step Manufacturing Process
Did you know: over 70% of U.S. broadband rollouts now depend on fiber networks that require high-precision manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment handles full-cycle fiber secondary coating line manufacturing, from choosing brand fibers like Fujikura or Corning SMF-28e to final test reports that ensure 100% quality assurance.
Our FTTH drop designs are built for overhead, underground, and direct burial installation, with low-smoke zero-halogen (LSZH), PVC, and PE jacket options and core counts from 1–4 cores. We supply single-mode OS1/OS2 and OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automated machines and high-precision equipment keep line speed steady and keep repeatability high. Typical lead times run four to five days for orders under 100 km and 7–10 days under 500 km, with an MOQ of 1 km and warranty for free replacement on quality issues.
Keep reading to see how materials, testing, and support work together to reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment provides complete production and laboratory testing for U.S. deployments.
- Multiple jacket choices and fiber grades cover varied installation environments.
- Automated production lines deliver consistent quality and reliable optical performance.
- Fast lead times, low minimums, and recognized brand fibers help plan procurement reliably.
- Comprehensive test reports and after-sales warranty back product reliability and documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides tailored drop solutions with full test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment pairs purpose-built equipment with tight material control. We provide custom builds and services for residential and MDU rollouts. Every order includes full QA coverage and complete test reports.
Our lab runs high heat, salt spray, and vibration tests to validate durability. Jacket options cover LSZH, PVC, and PE. Designs include bow-type flat and figure-8/self-supporting styles and support brand fibers such as Fujikura and Corning® SMF-28e.
- Controlled production lines and in-process checks for fully auditable shipments.
- Technical support for specs, trials, and ramp to volume.
- Modern fixtures and calibration minimize variation so every cable meets operator standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with rigorous test routines.
Fiber Selection & Brand Options
We select fiber ribbon line to minimum bend radius, attenuation, and install environment. Options include OS1/OS2 and OM2–OM4 and G.652D and G.657.A1/A2 per ITU-T. Brand fibers such as Fujikura® and Corning® SMF-28e are offered to meet procurement standards.
Strength Member Options
Strength members employ dielectric FRP or metallic steel wire. FRP is preferred where non-conductive runs are required. Steel wire provides tensile strength for longer aerial spans and bonding/grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for indoor flame safety, PVC for flexibility and ease of handling, and PE for outdoor UV and moisture resistance. Tight process control of temperature and capstan ratios stabilizes line speed and critical dimensions.
| Component | FRP | Metallic Steel |
|---|---|---|
| Use case | Electrical isolation | Aerial spans, high tensile |
| Advantage | Light, non-corrosive | High strength |
| Installation note | Easier terminations | Requires grounding |
In-Process and Final Testing
Inline geometry and concentricity checks operate in-line. Final optical tests confirm loss and return loss. Each order ships with a full test report and lab results from high-temperature, salt fog, and vibration tests to qualify field handling and drop terminations.
Typical lead times are under 100 km in 4–5 days and under 500 km in 7–10 days. Material lot records and FAI approvals provide traceability and compliance for U.S. projects.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment provides a focused portfolio of FTTH drop designs that cover tight indoor routes and exposed aerial spans. Each option pairs tested materials with geometry tuned for field termination and consistent optical performance.
The bow-type flat drop cable minimizes footprint for risers and conduit. It keeps bend loss low for easy routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose FRP (dielectric) for electrical isolation or steel wire when bonding and higher tensile strength are required.
Layouts & Strength Members
We provide dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and unitube flat types balance crush resistance and Fiber coloring machine for fast terminations.
Indoor/outdoor jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor UV and moisture resilience. Each family is qualified for mechanical/optical performance before shipment.
| Design | Application | Strength member | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | FRP (dielectric) | LSZH |
| Self-supporting (aerial) | Overhead spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment cut manual handling and boost throughput for drop patch preparation.
Our production line integrates automated machines that cut/strip drop cords to raise throughput and reduce operator variability.
The CLX-BPO2 automated stripper uses PLC + photoelectric control. One cycle is about 1.5 seconds, giving real-world speeds near 20 terminal operations per minute.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH and PVC jackets and trims FRP/steel members to precise stub lengths. Pneumatic cylinder actuators provide quick, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic and photoelectric sensors deliver precise positioning and feedback control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Feature | Capability | Benefit |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | High throughput |
| Actuation | Pneumatic cylinders | High speed and reliability |
| Material handling | LSZH/PVC; FRP/steel | Clean, accurate preps |
| Control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic feeders maintain clean workcells.
- Process control plans document calibration and key parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without compromising accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 provides industrial-grade strip/trim to our line, reducing cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to increase throughput and standardize prep quality. The unit runs at an approximate cycle time of 1.5 seconds, producing around 20 preps per minute in production.
PLC/photoelectric control deliver exact detection and repeatable actuation. That control keeps strip and stub lengths within tight tolerances.
Throughput & Cycle Time
Typical operation speed is 1.5s per cycle. This enables steady throughput under normal production conditions.
Jacket Strip & Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable strip length from 17.5–35.0 mm. Reserved strength member stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
FRP & Steel Member Handling
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Customized cutters are available for nonstandard sizes to maintain precision.
- Auto-eject scrap and sensor start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass simplify cell integration.
- Cylinder-driven motion and PLC/photoelectric control improve line reliability and lower maintenance interruptions.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0 to 11.0 mm | Meets strength and termination needs |
| Power & size | 110–220V, 50W; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 supports our lines in meeting volume targets without compromising quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures every order to fit your network requirements and simplify field rollout. We pair concise options with predictable manufacturing windows so your teams get install-ready reels.
Choose 1–4 core designs with SM or MM fiber. Options include OS1, OS2, and OM2–OM4 along with G.652D and G.657 variants to align with optics and connector plans.
We match sheath colors to Pantone codes for fast field ID and consistent asset tags.
Branding and Print Options
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom print legends and logos aid inventory/warranty tracking.
Lengths, Packaging & Special Builds
Standard reel lengths are 1 km, 2 km, and 4 km with custom reels and packaging to suit storage and handling. Choose flat bow-type or self-supporting and FRP or steel members to fit span and isolation requirements.
| Option | Common choice | Benefit |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Jacket | LSZH / PE / PVC | Indoor/Outdoor fit |
| Design | Bow-type / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye aligns runs to your schedule and provides docs that lists final specifications for easy on-site QA.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item ships with recorded acceptance data.
Environmental and Mechanical Tests
Our lab runs high-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials and assemblies. These tests recreate field stresses for indoor and outdoor use.
Full Test Reports for Every Reel
Every fiber optic cable includes a 100% test report that logs attenuation, return loss, and geometry where applicable. Final QC gates prevent nonconforming shipments before they leave the factory.
Audit Trail and Compliance
Lot/batch records tie test data to reels and serials so audits and claims are easy to verify. Documentation follows common customer templates to accelerate approvals and receiving inspection.
- Line checks and final inspection prevent field failures and lower warranty events.
- Quality packages include spec confirmation and formatted test data for quick review.
- Ongoing trend analysis inform preventive maintenance and improve long-term reliability.
| Trial | Purpose | Outcome |
|---|---|---|
| High-temperature | Material stability | Validated heat endurance |
| Salt spray | Corrosion robustness | Qualified for outdoor use |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
Cost Drivers and Pricing
Budget planning for a drop begins with fiber/jacket selection and is refined by volume and customization.
Typical prices vary widely—from about $30 to $1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket material, reel length, and structural design.
Primary Cost Inputs
The primary cost drivers are fiber grade, sheath material, and the chosen structure for deployment.
Self-supporting structures and steel strength elements increase material/labor. Custom sheath colors/logos/legends add setup time and influence price for short runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes reduce unit cost. Short runs often include setup charges and higher unit prices.
- Changeovers and special cutters extend lead time and add cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Factor | Price impact | Guidance |
|---|---|---|
| Fiber grade | Large | Balance spec vs. budget |
| Jacket type | Medium | Evaluate LSZH vs PE |
| Order length / volume | Large | Consolidate runs to cut unit cost |
Logistics for the U.S.
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align staffing and sites. Predictable windows cut downtime and help control cost when a rollout is underway.
Scheduling & Capacity Planning
Typical production windows run 4–5 days for orders under 100 km and 7–10 days for orders under 500 km. We schedule line capacity to match your rollout milestones and to maintain on-time delivery.
The service team issues production updates and tracking so installation teams know when reels arrive. For compressed schedules, we reserve contingency capacity to accelerate critical-path orders.
MOQ and Rationale
The MOQ is 1 km. This reflects line setup such as wire and jacket die adjustments that consume start-up material and scrap.
We review your put-ups and staging to choose reel sizes that cut waste and handling. Staggered batches can balance inventory with frequent, smaller deliveries to job sites.
Installation readiness and application scenarios
On-site conditions determine whether a self-supporting aerial, ducted pull, or direct burial is the right choice for a project.
Aerial, duct, and direct-buried deployment considerations
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with appropriate members to control sag and tension for long-term stability.
Duct installations perform best with low-friction sheaths and crush-resistant builds so pulling avoids fiber damage. PE jackets are common for underground and buried paths where moisture resistance matters.
Direct-buried designs require proper depth control per local codes and moisture barriers to protect the optic core over time.
Indoor riser/plenum distribution and ONT termination
Indoor riser and plenum routes favor LSZH jackets to meet smoke/flame codes. Flat drop profiles strip clean and present controlled stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware compatibility. Standardized line prep reduces install time and reduces scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct-buried | PE with moisture barrier | Follow local depth and warning tape rules |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach delivers a consistent installation across indoor outdoor transitions. That reduces callbacks, faster activations, and stable field performance for your system.
Support from Spec to Service
Our team coordinates testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements capture through approved drawings and pre-production builds. We deliver documentation templates and clear installation notes so field crews work from the same plan.
After-sales service includes fast response, RCA, and corrective action. All products ship with full test reports and traceability to help QA acceptance.
- Round-the-clock availability for status and technical support.
- Warranty includes free replacement for confirmed quality issues.
- Schedule coordination for expedites and urgent changes.
- Config control so shipped items match agreed requirements every time.
| Support area | What we do | Outcome |
|---|---|---|
| Tech/Eng | Specs + pilots | Reduced field issues |
| QA/Testing | Lab trials & 100% test reports | Traceable quality |
| Service | Rapid replacement & root-cause | Lower downtime |
Final Thoughts
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We provide custom FTTH drops that pair material choices with validated manufacturing and lab testing. Every reel ships with a 100% test report and documented lab trials to support U.S. field acceptance.
A robust production line, including CLX-BPO2-enabled prep machines, cuts variability and speeds turnaround. Our equipment and machines standardize strip/stub lengths so installers get consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance performance and cost to extend service life. Dedicated customer support guides scheduling, logistics, and after-sales care so your deployment stays on plan.
Contact Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every fiber optic and optic cable shipment with lab validation and responsive service.